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Old 10-22-2020, 12:32 AM   #11
Cartmaster
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Default Re: 1991 EZGO Marathon Build

I have seen it too many times to have missed that LOL. it looks like it has had a torch applied to it and a big hammer too.

Yes sir, 2 x 1, stock thickness is 1/8 standard, but i used to use 3/16 when i built my own axles. One word of warning though, when you cut the ends off the old axle, clean up the part that welds to the tube and make sure they are true and square. If not, you can make new ones easily out of i think 4" box cut to size and remove one long side to get the shape you need and carefully drill for the axle pins. Dont quote me on the tube size though.

You could make the axle a little wider and extend the tracking arms to suit as well, this will give you a bit wider track for the front end and also allow you to use wider tyres as long as they dont rub on the spindle arms.

If you are looking to put taller tyres on, you can create your own lifted axle by welding 3 peices cut at angles to create the drop. but again, measure and cut carefully.

If you use the TXT front springs to move the axle forward, buy four of the clamp plates for TXT with three holes instead of using the existing ones. weld two to the top of the axle and use the other two for clamping the springs on.

Tyres! = tires! Im british LOL
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Old 10-23-2020, 10:33 AM   #12
BLK MAJK
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Default Re: 1991 EZGO Marathon Build

Some goodies showed up yesterday!
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Old 10-25-2020, 06:23 PM   #13
BLK MAJK
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Default Re: 1991 EZGO Marathon Build

Did some work yesterday while I'm still waiting on parts. I had seen a post where someone made plates to move the front leaf spring mounts backward to gain more wheel well clearance instead of buying the longer TXT leafs. I had the material, so I figured I'd try it. It came out pretty well and I think it will alleviate the issue with the tires rubbing the wheel well on bumps when the suspension articulates to one side. Ignore the one extra hole, I changed my mind how to set the plates up, and I'll probably fill it in later, but it certainly won't hurt anything.
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Old 10-31-2020, 07:16 AM   #14
BLK MAJK
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Default Re: 1991 EZGO Marathon Build

Things just got real!

Batteries came in. I'll be wiring them together today to let them balance while I work on the box and wait for the BMS. I made the bus bars yesterday and more parts came in. I think by Monday the only thing I still need to arrive is my BMS
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Old 10-31-2020, 08:42 AM   #15
slonomo
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Default Re: 1991 EZGO Marathon Build

Very cool build! Nice fab skills, I like the plates for the leaf springs, good idea. Bookmarked
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Old 12-22-2020, 10:35 AM   #16
firestop2
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Default Re: 1991 EZGO Marathon Build

Quote:
Originally Posted by BLK MAJK View Post
Did some work yesterday while I'm still waiting on parts. I had seen a post where someone made plates to move the front leaf spring mounts backward to gain more wheel well clearance instead of buying the longer TXT leafs. I had the material, so I figured I'd try it. It came out pretty well and I think it will alleviate the issue with the tires rubbing the wheel well on bumps when the suspension articulates to one side. Ignore the one extra hole, I changed my mind how to set the plates up, and I'll probably fill it in later, but it certainly won't hurt anything.
I know it's been a while but I was wondering how the mod you made for moving the axle forwarded held up? Also, did you ever replace the axle? My 92' marathon has a bent axle and Im considering making a new one.
Another question regarding swapping to TRX springs, If I fab my own front axle, what geometry changes would need to be made to make it work? Need to replace springs anyway.
Thank you all for input!
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Old 01-01-2021, 11:20 AM   #17
B Swan
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Default Re: 1991 EZGO Marathon Build

Quote:
Originally Posted by Cartmaster View Post
Looking at the front shot of your cart, it looks like there might be a slight bend in the axle on the passengers side, If so, it will not help with the tires rubbing the arches.
How could you tell? And that, just by looking at a photo!? I think something’s wonky with the front wheel/axle/tire area of my cart, but I’m not sure. So, how could you tell?
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Old 01-02-2021, 06:06 AM   #18
Cartmaster
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Default Re: 1991 EZGO Marathon Build

I have a special tool to help me. Its a pair of glasses I put on when looking at pictures and helps me to see things that are either straight or bent.

Sorry, just kidding. But really! I just notice these things lol.

If you can't see anything obviously wrong with yours, post pictures, then we can take a look. Take various angles etc to see if we can see anything. A better description of the symptoms would help too. "Something wonky" is a bit too vague!
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Old 01-04-2021, 08:47 AM   #19
BLK MAJK
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Default Re: 1991 EZGO Marathon Build

Quote:
Originally Posted by firestop2 View Post
I know it's been a while but I was wondering how the mod you made for moving the axle forwarded held up? Also, did you ever replace the axle? My 92' marathon has a bent axle and Im considering making a new one.
Another question regarding swapping to TRX springs, If I fab my own front axle, what geometry changes would need to be made to make it work? Need to replace springs anyway.
Thank you all for input!
The mod to move the axle forward is working perfectly, no issues and it solved the issue with the tires rubbing on the body. I do see some rub on the leaf spring at full lock, but that is a combination of tire design and wheel offset. I've been working a ton on our new house, so the cart hasn't taken a high priority. I have no built a new axle yet, but I think I still plan to eventually.
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Old 01-04-2021, 08:54 AM   #20
BLK MAJK
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Default Re: 1991 EZGO Marathon Build

Time for an update. As I stated in my previous post, we got a new house over the summer and I have been spending much of my free time working on that. New windows, new flooring, new cabinets, etc, etc. I did manage to get some work done though...

Got the wiring for the battery all temporarily done and communicating properly. I still have to finalize some of the major connections, but it all tests ok. If you look at the screenshot of the cells, you will see 1 that is a bit lower than the others. It has since balanced out and it within 0.007vdc of the others. I expect it to be even closer after a few charge/discharge cycles.
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